Metal and Bone Drilling - The Thermal Aspects by Albert J. Shih & Bruce L. Tai & Rui Li

Author:Albert J. Shih & Bruce L. Tai & Rui Li
Language: eng
Format: epub
ISBN: 9783030260477
Publisher: Springer International Publishing

Rui Li

Keywords

High-speed drillingHigh-throughput drillingMinimum quantity lubricationDeep-hole drillingWorkpiece temperature

Cast irons have been broadly utilized in engineering applications. In the automotive industry, gray iron (GI), as known as the gray cast iron , is often used for engine blocks due to its high thermal conductivity and damping capability. Nodular iron, also known as ductile iron, has a higher strength and toughness than GI, and is used for many high-loading components such as crankshaft, gears, and axles. A compromise between GI and nodular iron (or the nodular cast iron) is the compacted graphite iron (CGI), which is known for its high strength for making engine smaller, stronger, and lighter. A smaller and lighter engine enables better vehicle fuel efficiency. Drilling of GI is not particularly difficult because of the graphite inside. Graphite is a natural solid lubricant which can reduce the friction between the cutting edge and workpiece. Also, GI has a high melting point to avoid the edge built-up or chip-recasting issues that occur in aluminum drilling. However, due to the high strength of CGI, excessive heat generated from material removal and chip interactions with the tool can be detrimental to the drill.

This chapter presents two sets of experimental studies on dry and minimum quantity lubrication (MQL) drilling with shallow and deep holes. The first study is focused on high-speed (high-throughput) shallow hole drilling of CGI between dry and MQL conditions. The second example is focused on deep-hole drilling (without pecking cycle) of nodular irons under various MQL conditions. All tested are conducted with the state-of-the-art coated solid WC-Co drills. Detailed experimental methods and key results are presented in the following sections.

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